Fuel heating apparatus and methods

Abstract

A method of improving fuel efficiency in a diesel fuel internal combustion engine on a vehicle includes providing a combustion system including a fuel tank, an engine, and a fuel line disposed between the fuel tank and the engine. A heat exchanger is positioned on the fuel line between the fuel tank and the engine. Working thermal fluid is passed from a reservoir through the heat exchanger while fuel is passed through the heat exchanger, increasing the temperature of the fuel passing through the heat exchanger. A vibration isolation mount is installed between the heat exchanger and the vehicle, thereby reducing vibration of the heat exchanger during use of the vehicle. Heated fuel from the heat exchanger is delivered to the engine, improving the fuel efficiency of the engine by burning the heated fuel.

What is claimed is: 
     
       1. A method of improving fuel efficiency in vehicle, comprising the steps of:
 providing a combustion system including a fuel tank, an engine, and a fuel line disposed between the fuel tank and the engine; 
 providing a heat exchanger on the fuel line between the fuel tank and the engine, wherein the heat exchanger includes a heat exchanger supply coupling, a heat exchanger return coupling, a first fuel line connector, and a second fuel line connector; 
 providing a heat exchanger reservoir on the vehicle, wherein the fuel line includes a fuel supply line upstream of the heat exchanger and a heated fuel line downstream of the heat exchanger; 
 connecting the first fuel line connector to the fuel supply line on the fuel line upstream of the heat exchanger; 
 passing fuel from the fuel supply line to the heat exchanger via the first fuel line connector; 
 connecting the second fuel line connector to the heated fuel line on the fuel line downstream of the heat exchanger; 
 passing fuel out of the heat exchanger to the heated fuel line via the second fuel line connector; 
 simultaneously passing working thermal fluid from the heat exchanger reservoir into the heat exchanger at a first flow rate via the heat exchanger supply coupling, through the heat exchanger, and returning the working thermal fluid from the heat exchanger to the heat exchanger reservoir via the heat exchanger return coupling such that the working thermal fluid transfers heat to the fuel inside the heat exchanger prior to delivery of the fuel to the engine for combustion, wherein the working thermal fluid does not contact the fuel inside the heat exchanger; 
 increasing the temperature of the fuel passing through the heat exchanger, wherein the fuel is heated in the heat exchanger; 
 monitoring the temperature of the heated fuel using a temperature sensor, wherein the temperature sensor includes a thermocouple attached to a support rod; 
 updating, via a flow controller, the simultaneous passage of working thermal fluid from the heat exchange reservoir into the heat exchanger to occur at a second flow rate different than the first flow rate based on the monitored temperature of the heated fuel; 
 providing a first vibration isolation mount installed between the heat exchanger and the vehicle; 
 reducing vibration of the heat exchanger via the first vibration isolation mount; 
 delivering the heated fuel from the heat exchanger to the engine; and 
 improving the fuel efficiency of the engine by burning the heated fuel. 
 
     
     
       2. The method of  claim 1 , wherein the working thermal fluid is heated engine coolant from the engine. 
     
     
       3. The method of  claim 2 , wherein the fuel is heated in the heat exchanger to a temperature between about 180 degrees F. and about 210 degrees F. 
     
     
       4. The method of  claim 2 , wherein the method further comprises reducing exhaust pollutants from the internal combustion engine. 
     
     
       5. The method of  claim 4 , wherein the method further comprises:
 providing a fuel filter, wherein the support rod is disposed in the fuel filter; and 
 heating the fuel inside the fuel filter as the fuel passes through the fuel filter. 
 
     
     
       6. The method of  claim 4 , further comprising providing a second vibration isolation mount installed between the heat exchanger and the vehicle. 
     
     
       7. The method of  claim 6 , further comprising reducing vibration of the heat exchanger via the second vibration isolation mount. 
     
     
       8. A vehicle apparatus, comprising:
 a vehicle; 
 an engine disposed on the vehicle; 
 a fuel tank disposed on the vehicle; 
 a fuel line disposed on the vehicle between the engine and the fuel tank; 
 a heat exchanger reservoir disposed on the vehicle; 
 a heat exchanger disposed on the vehicle between the fuel tank and the engine, the heat exchanger including a heat exchanger supply coupling, a heat exchanger return coupling, a first fuel line connector, and a second fuel line connector; 
 a temperature sensor disposed downstream of the heat exchanger, wherein the temperature sensor includes a thermocouple attached to a support rod; 
 a flow controller disposed upstream of the heat exchanger; 
 a vibration isolation mount positioned between the heat exchanger and the vehicle; and 
 the fuel line including a fuel supply line upstream of the heat exchanger and a heated fuel line downstream of the heat exchanger; 
 wherein the heat exchanger supply coupling is connected to the heat exchanger reservoir and is configured to supply a flow of working thermal fluid to the heat exchanger from the heat exchanger reservoir, 
 wherein the heat exchanger return coupling is connected to the heat exchanger reservoir and is configured to return working thermal fluid to the heat exchanger reservoir from the heat exchanger, 
 wherein the temperature sensor is configured to monitor a temperature of the heated fuel line, 
 wherein the flow controller is configured to adjust the flow of working thermal fluid to the heat exchanger from the heat exchanger reservoir based on the temperature of the heated fuel line, 
 wherein the first fuel line connector is connected to the fuel supply line on the fuel line upstream of the heat exchanger and is configured to provide fuel to the heat exchanger, and 
 wherein the second fuel line connector is connected to the heated fuel line on the fuel line downstream of the heat exchanger. 
 
     
     
       9. The apparatus of  claim 8 , wherein the engine is a diesel engine. 
     
     
       10. The apparatus of  claim 9 , wherein the second fuel line connector and heated fuel line are configured to supply heated fuel from the heat exchanger to the engine. 
     
     
       11. The apparatus of  claim 10 , further comprising a fuel filter disposed on the fuel line upstream of the heat exchanger, wherein the support rod is disposed inside the fuel filter. 
     
     
       12. The apparatus of  claim 11 , wherein the heat exchanger is configured to improve the fuel efficiency of the engine by heating fuel passing through the heat exchanger. 
     
     
       13. The apparatus of  claim 9 , wherein the heat exchanger is configured to improve the fuel efficiency of the engine by heating fuel passing through the heat exchanger. 
     
     
       14. The apparatus of  claim 12 , wherein the heat exchanger is configured to increase the temperature of the fuel passing through the heat exchanger by up to forty degrees F. 
     
     
       15. The apparatus of  claim 13 , wherein the heat exchanger is configured to increase the temperature of the fuel passing through the heat exchanger by up to forty degrees F. 
     
     
       16. The apparatus of  claim 12 , wherein the heat exchanger is configured to heat the fuel passing through the heat exchanger to a temperature between about 180 degrees F. and about 210 degrees F. 
     
     
       17. The apparatus of  claim 13 , wherein the heat exchanger is configured to heat the fuel passing through the heat exchanger to a temperature between about 180 degrees F. and about 210 degrees F.